Minipack-torre S.p.A. Via Provinciale, 54 - 24044 Dalmine (BG) - Italy

Tel. (035) 563525 – Fax (035) 564945 E-mail: info@minipack-torre.it

http://www.minipack-torre.it IT ISTRUZIONI PER L’USO E LA MANUTENZIONE EN INSTRUCTIONS FOR USE AND MAINTENANCE DE ANWEISUNGEN ZUR BEDIENUNG UND WARTUNG

Pratika 56 (MF21BA54)

Pratika 56 CS (MF23BA80)

Pratika 56 MPE (MF23BA81, MF23BA82, MF23BA63, MF23BA68, MF23BA65*)

Pratika 56 MPS (MF23BA83, MF23BA84)

Versione HMI 3.00 / HMI 3.00 version / Version HMI 3.00 Pratika 56 Pratika 56 CS Pratika 56 MPE Pratika 56 MPS

Valido dalla matr. / Valid from s.n. / Gültig ab Seriennr. 1534 (07.2014) 1525 (06.2014) 1526 (06.2014) 1505 (04.2014)* xxxx (xx.2014)

IT LEGGERE ATTENTAMENTE QUESTE ISTRUZIONI PRIMA DI USARE LA MACCHINA EN BEFORE USING THE MACHINE PLEASE CAREFULLY READ THE INSTRUCTIONS DE BITTE LESEN SIE DIESE ANLEITUNG GENAU DURCH, BEVOR SIE DIE MASCHINE BENÜTZEN IT Italiano Pagina 01

DOC. N. FM111147 REV. 01 ED. 11.2014

EN English Page 30

DE Deutsch Seite 59

TRANSLATION OF THE ORIGINAL INSTRUCTIONS

Contents EN

Chapter 1. Description Page 1.1. Preface 31 1.2. Machine features 31

Chapter 2. Film features 2.1. Films to be used 32 2.2. Band A calculation 32

Chapter 3. Machine usage conditions 3.1. Max. pack sizes 32 3.2. Items that may be packaged 32 3.3. Items which must not be packed 32

Chapter 4. Safety standards 4.1. Warnings 33 4.2. Individual protection devices 33 4.3. Guards 34 4.4. Residual risks 34

Chapter 5 Machine adjustment and setting up 5.1. Control panel 35

5.1.1. Main keys (icons) 36 5.1.2. Luminous column 37

5.2. Start-up 37 5.2.1. Machine operating modes 38 5.2.1.1. AUTOMATIC mode 38 5.2.1.2. MANUAL mode 38 5.2.2. Password 39 5.2.3. Creation of a new AUTOMATIC PROGRAM 40 5.2.4. Parameter settings for the AUTOMATIC PROGRAM (from the "Data" key) 41 5.2.5. Parameter settings for the AUTOMATIC PROGRAM (from "graphic") 45 5.2.6. Choosing the AUTOMATIC program 46 5.2.7. Parameter settings for the MANUAL PROGRAM 47 5.2.8. Deleting a program 48 5.2.9. Choose the language 48 5.2.10. Pause time 48 5.2.11. Partial and stock counter 49 5.2.12. Backup programs 49

5.3. Alarms 50 5.4. Introducing of the film 52 5.5. Adjustments 55

5.5.1. Adjusting the infeed belt 55 5.5.2. Adjusting the photocells 55 5.5.3. Adjusting the film raiser bar 55 5.5.4. Adjustment of film opening bar 56

5.6. Packaging 56 Chapter 6. Ordinary maintenance

6.1. Precautions and setting to maintenance mode 57 6.2. Maintenance table 57

6.2.1. Routine maintenance plan 57 6.2.2. Maintenance plan of safety devices 57

6.3. Disassembling, demolition and elimination of residuals 58 Chapter 7. Guarantee

7.1. Certificate of guarantee 58 7.2. Guarantee conditions 58

CE DECLARATION OF CONFORMITY 88

Machine installation instructions (see attachment) Wiring diagram (see attachment) Pneumatic diagram (see attachment) (Pratika 56, 56CS only)

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Chapter 1. Description EN 1.1. Preface This manual has been drawn up in compliance with the UNI10893 standard dated July 2000. It is meant for all users in order to enable them to use the machine correctly. Keep it in a place which can be easily accessed in the proximity of the machine and which is known to all users. This manual is an integral part of the machine for safety reasons. We wish to specify the symbols in use here below in order to improve understanding of them.

ATTENTION: Accident prevention rules for the operator. This warning indicates the presence of dangers which can injure the person operating on the machine.

ATTENTION: Hot parts. Shows the danger of burning, thus involving the risk of a serious accident for the exposed person.

WARNING: It indicates the possibility of damaging the machine and/or its components.

1.2. Machine features The L-sealer “Pratika 56” has been designed to wrap loose, individual or groups of products (foodstuff, household item, toys etc.) using single fold heat shrink film. The machine can be fed manually or operate in series with other machinery. If it is fed by a qualified technician (machine operator) he needs to be instructed accordingly, and he has to be able to advise it can maintenance technician in case of malfunctions or machine anomalies. Operate in “AUTOMATIC” mode. The machine is managed by a control logic housed in the PLC. Thanks to the versatile design of the machine, a wide range of products can be processed with different shapes and sizes. Moreover it is possible to perform operations, using “MANUAL” mode controls. Packs are handled by conveyors housed inside the framework. The machine is also equipped with a device for the recovery of scrap film, to avoid the presence of waste film inside the operator work zone. TECHNICAL DATA Package sizes (mm) 2940 x 1440 x 1870 Package weight (Kg) Pratika 56: 721 Pratika 56CS: 806 Pratika 56MPE: 813 Pratika 56MPS: 813 Machine weight (Kg) Pratika 56: 671 Pratika 56CS: 756 Pratika 56MPE: 763 Pratika 56MPS: 763 Maximum production (packages/hour) Pratika 56: 2400 Pratika 56CS: 2400 Pratika 56MPE: 3600 Pratika 56MPS: 2400 Pneumatic supply 120 l/min (Pratika 56, 56CS only)

31

Chapter 2. Film features EN 2.1. Films to be used The machine can work with all heat shrink and non-heat shrink films, from 15 to 50 microns in thickness, of a technical and food type. To guarantee the best results, it is recommended to use the films marketed by us. The special features of our films assure their outstanding reliability, with regard both to compliance with laws in force and to an excellent machine performance.

A = mm700 MAX D = mm300 MAX

Consult the data and safety sheets of the films in use and observe the corresponding instructions!

2.2. Band A calculation Band A = b + c + 100mm By band “A” we mean the width that the film must have to package the product. Note: it may be necessary to increase the amount of film friction (100mm) indicated in the formula, for high products or with complex shape.

Chapter 3. Machine usage conditions EN 3.1. Max. pack sizes Pratika 56 a = 600mm b = 400mm c = 160mm Pratika 56 CS a = 600mm b = 400mm c = 240mm Pratika 56 MPE a = 600mm b = 400mm c = 240mm Pratika 56 MPS a = unlimited b = 400mm c = 240mm Note: measurements shown refer to the maximum for the single dimension. Refer to chapter 2.2. to get max. dimension of pack (b x c); the addition of (b + c) is equal to film roll width minus 100mm.

3.2. Items that may be packaged These machines are capable of packing a wide range of completely different products. They are used successfully in the following sectors: food, marketing, graphics and mailing, large distribution, industry, fabrics. 3.3. Items which must not be packed The products listed below must absolutely not be wrapped to avoid permanent damage to the machine and serious injuries to the operator:

• Wet and unstable products • Liquids of any kind and density in fragile containers • Flammable and explosive materials • Pressurised gas cylinder of any kind • Loose and volatile powders • Any materials and products not listed but which might harm operator and damage the machine.

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Chapter 4. Safety standards EN 4.1. Warnings It is extremely important to read this entire chapter as it contains important information regarding risks that personnel are subject to in the event of incorrect use of the machine. These basic standards must be observed as well as specific standards applicable in the country of installation. • The machine must be installed by trained and authorised technicians. • This machine is not intended for use by persons (including children) with reduced physical, sensory or mental

capabilities, or lack experience and knowledge, unless they have been given supervision or instruction concerning use of the machine by a person responsible for their safety.

• Children should be supervised to ensure that they do not play with the machine. • Never use the machine for purposes other than as specified in the sales contract. • Never allow unauthorised personnel to perform repairs or other operations on the machinery. • The operator must be familiar with all warnings related to the tasks in hand and always be informed by the head of

the site regarding risks. • Ensure that all clothing is tight fitting, with particular reference to cuffs or other loose clothing. • Ensure that all operating areas and transit zones are kept clear, clean and adequately lit at all times. • Eliminate all safety hazard conditions before using the machine and always notify the head personnel of any

malfunction. • Never use the machine in the event of fault. • Never tamper with safety devices or circuits. • Never perform modifications on the machine without prior authorisation from the manufacturer. • If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified

persons in order to avoid a hazard. • The electrical enclosure must remain closed during operation. • The key to open the electrical enclosure must be kept by a specialised and authorised member of personnel. • Smoking is forbidden while the machine is operating! • Never performs maintenance and/or adjustments to the machine during operation. Guards may only be

disassembled by suitably trained and qualified maintenance engineers. • Never operate the machine without all guards fitted. Ensure correct position of all guards before resuming normal

operation. • The manufacturer declines all liability for damage or phisical injury caused by failure to observe safety standards.

CAUTION! This machine is NOT designed for explosion-proof applications; it is a standard model and therefore must never be installed or operated in zones subject to the risk of explosion.

4.2. Individual protection devices

Wear safety shoes that protect feet from impacts, crushing and compression while moving or handling the machine.

Wear safety gloves that protect the hands from crushing and mechanical hazards and while moving or handling the machine.

Wear safety gloves that protect the hands against cutting risks while changing the sealing blades.

Wear safety gloves that protect the hands against the specific risks associated with the materials to be packed (mechanical, chemical) and against coming into contact with the high temperatures present on the seals and/or sealing blade (up to 200°C).

Wear safety gloves that prevent the hands from coming into contact with foodstuffs when packaging them.

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Chapter 4. Safety standards EN 4.3. Guards

The machine is equipped with a front guard (C1) and a back guard (C2) which stop the machine when they are opened. To start the machine up again follow the instructions provided in paragraph 5.3 (see note for alarm “A002: GUARDS OPEN”). 4.4. Residual risks Comply with the following prohibitions and warnings.

Dragging hazard! Hazard generated by moving elements (conveyor belts, motor driven rollers) in the event of contact during operation phases.

Burn hazard! Risk due to hot sealing knives for film. Before performing operations in these zones, set the machine to “maintenance mode”, and wait for resistances to cool. Never perform operations without suitable personal protective equipment such as gloves and overalls.

Electric shock hazard! Sealing unit: risk due to electric energy inside sealing unit (Pratika 56 MPS only). Electric control board: risk due to electric energy inside electrical control board (in terminal board of main switch and on terminals at switch inlet)

Before performing maintenance: switch the machine off by rotating the main switch (Q1) to “0” (OFF) remove the plug from the mains socket WAIT 15 minutes to allow the capacitors to discharge.

The wheels must be used only for moving the unit short distances across smooth, horizontal floors.

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Chapter 5. Machine adjustment and setting up EN 5.1. Control panel The machine is equipped with a touch control panel where it is possible to set all operation and programming features.

Only use one finger to select an object on the panel for correct touch panel use. If the panel is pressed in two or more points at the same time it is possible that you select an object unintentionally.

Q1 Main switch.

D Display. Displays selected functions and relative settings.

S1 “EMERGENCY buttons. Both buttons immediately stop the machine in case of immediate danger or to “place it in maintenance conditions”. If they are pressed, they need to be turned clockwise to release them.

S2 Button “RESET”. Press when starting up the machine. Reset the machine after the “EMERGENCY” pushbutton and the A001 alarm have been activated.

S3 “BYPASS SAFETY PROTECTIONS” selector. If this selector switch is set to OFF, the machine may only be operated if the guards are closed (AUTOMATIC program). If this selector switch is set to ON, the machine may be operated with the guards open. This condition is necessary “only” when carrying out the set-up procedures and when inserting or changing the film reel (MANUAL program only).

E Luminous column. The combination of the colours and buzzer signal the machine status at all times.

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Chapter 5. Machine adjustment and setting up EN 5.1.1. Main keys (icons)

Key Description Key Description

Setup

Previous page

Program configuration

Confirm password

Manual/Automatic Selector

Alarm reset

Main (home page)

Alarm siren switch off

Alarm

Alarm information

Program backup/restore (USB)

PLC diagnosis

Parameter setting/display from "Graph" (quick selection parameters)

Save program

Parameter setting/display from “Data”

Load program

Previous page

Delete program

Next page

New program

Login (user authentication)

Conveyor belt movement and execution of film feed/winder/unwinder

Logout

Sealing

Users and password management

Product ejection

Choosing the language

Product counter

Home page (company logo)

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Chapter 5. Machine adjustment and setting up EN 5.1.2. Luminous column The machine is equipped with a luminous column with multicolour LED lights (green, yellow, red) which, based on the combination of colours and buzzer, signals the machine status at all times.

Machine status

Luminous column

Buzzer

Start in Manual Start in Automatic

Green No

Green

Green Warm-up Maintenance Automatic stop Manual stop Homing

Yellow No

Yellow

Yellow No power

Red Yes

Red

Red Safety excluded during Start

Red Yes

Green

Green Safety excluded during Stop

Red Yes

Yellow

Yellow Roll end in Automatic Start

Red Yes

Green

Green 5.2. Start-up Turn the main switch (Q1) into pos. 1 and press the “RESET” (S2) button. The display switches on and the screen with the “minipack-torre” logo appears. Press the logo. The main screen is displayed:

When the machine is switched on, the numbers that indicate the temperature of the front and side sealing bars start flashing. Once the bars have reached the programmed temperature, they stop flashing. Until the bars reach this temperature, the cycle may only be started in MANUAL mode (not AUTOMATIC mode). During the heating phase the "Alarm" button is red since the "A024: MACHINE HEATING" alarm is active. Once the set temperature has been reached, the alarm resets itself and the button becomes green..

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Chapter 5. Machine adjustment and setting up EN 5.2.1. Machine operating modes The machine can be operated in 2 modes: AUTOMATIC, MANUAL. 5.2.1.1. AUTOMATIC mode This is the completely automatic machine operating condition.

Press the START button to start the automatic cycle. AUTO / MAN : Press this button to alternate between the MANUAL and AUTOMATIC programs.

The above screen illustrates the operating condition in Automatic STOP mode.

Press the STOP button to stop the automatic cycle.

The above screen illustrates the operating condition in Automatic START mode. 5.2.1.2. MANUAL mode This condition is necessary when carrying out the set-up procedures and when inserting or changing the film reel. In this phase, you can open the guards by turning the selector key (S3) to the ON position. The "Alarm" button is red since the "A002: OPEN GUARDS" alarm is active. By turning the selector (S3) to the OFF position, the alarm resets itself and the button becomes green.

Press the START button to switch to “CONDITION: Manual START” and enable the belt, expulsion of the last product and the sealing function. AUTO / MAN : Press this button to alternate between the MANUAL AND AUTOMATIC programs.

The above screen illustrates the operating condition in Manual STOP mode.

Press the STOP button to switch to “CONDITION: Manual STOP”. The infeed belt, outfeed belt, film feeder and film winder and unwinder all run while this button is pressed. By pressing this key, an entire sealing cycle is performed. By pressing this key, the final sealing process is performed and the belt subsequently ejects the last packaged product (Pratika 56 MPS only).

The above screen illustrates the operating condition in Manual START mode.

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Chapter 5. Machine adjustment and setting up EN 5.2.2. Password Some functions are password protected to guarantee the correct operation of the machine and to prevent the operator from erroneously modifying the PLC program which controls all the operations. There are 3 password levels, each of which is protected by a different Name and Password. • Operator (first level), • Maintenance technician (second level), • Factory (third level). "Operator" Password (first level)

Menu protected by "Operator" password (first level)

"Maintenance technician" and "Factory" Passwords (second and third levels)

Menu protected by "Factory" password (third level) Menu protected by "Maintenance technician" password (second level)

"Operator" Password Release (first level) The operator must know the first level Name and Password to release the Password.

The "padlock" symbol next to a key indicates the function is Password protected. To unlock it, follow the procedure below.

Press the password protected key.

Press the “Name” button.

If the “Name” is composed of letters, enter the letters and press Enter. If the “Name” is composed of letters and numbers (or only numbers), press the “123” button.

Enter the numbers that make up the name and press Enter.

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Chapter 5. Machine adjustment and setting up EN Enter the “Password” in the same way.

Once you have entered the “Name” e and the “Password” press these two buttons in the sequence indicated in order to access the display screens.

Note: the padlock symbol next to the symbol disappears.

Password Reset To restore programme security with a password follow the procedure described below.

From the initial screen press the “Setup” button.

Press the “Logout” button and then the button “Main”.

The "padlock" symbol has re-appeared indicating that the programme is protected with a password.

5.2.3. Creation of a new AUTOMATIC PROGRAM The machine normally works in automatic cycle. The machine is provided with an already memorised automatic program (P1), but with standard parameters. We recommend creating a new program with the specific settings for your product, before packing it. To create a new program, proceed as follows.

Press the “Program configuration” button.

Press the “New” button.

To rename the just copied new program, click on the name (e.g. r3) and type in the new name. Press Enter then the “Save” button.

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Chapter 5. Machine adjustment and setting up EN 5.2.4. Parameter settings for the AUTOMATIC PROGRAM (from the ''Data'' key)

Press the “Data” button.

At this point the programmable parameters display page appears; press the button to scroll through the various pages:

PACKET HEIGHT [mm] 56 56CS 56MPE 56MPS Adjusts triangle aperture. Values: 35 ÷ 240.

PACKET LENGTH [mm] 56 56CS 56MPE 56MPS If it is set on AUTO the film will be sealed when the photocell reads the end of the product. This is recommended for products with a regular shape. If it is set on MAN the function deactivates the photocell reading of the end of the product. In this case the film is sealed by setting the “PACKET LENGTH” variable. Values: 1 ÷ 600.

FRONT FILM [mm] 56 56CS 56MPE 56MPS Adjusts the quantity of film to leave in front of the pack. Values: 0 ÷ 300.

REAR FILM [mm] 56 56CS 56MPE 56MPS Adjusts the quantity of film to leave behind the pack. Values: 0 ÷ 900.

To modify the set values (e.g. FRONT FILM from 20mm to 30mm) follow the procedure below.

Indicates the minimum variable setting. Indicates the maximum variable setting.

Press the numerical value (e.g. 20).

Enter the new value and press “Enter”.

Press and scroll the next screens.

FRONT TEMPERATURE [C] 56 56CS 56MPE 56MPS Adjusts the front bar (short) sealing temperature. Values: 0 ÷ 240.

SIDE TEMPERATURE [C] 56 56CS 56MPE 56MPS Adjusts the side bar (long) sealing temperature. Values: 0 ÷ 240 (Pratika 56, 56CS, 56MPE); 0 ÷ 365 (Pratika 56MPS).

SEALING TIME [s] 56 56CS 56MPE 56MPS Adjusts the bar sealing time. Values: 0 ÷ 3.

SEALING HEIGHT [mm] 56CS Adjusts the sealing position with respect to the belt. Values: AUTO / MAN. If set at AUTO sealing is performed at half the height of the product. Ideal for standard products. If set at MAN sealing is performed at the set measurement (measured starting from outfeed belt surface). Values: 0 ÷ 120.

SEALING PRESSURE 56MPE 56MPS Regulates the pressure of the film sealing bar to optimise the cut. Values: MIN / MED / MAX

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Chapter 5. Machine adjustment and setting up EN

SEALING HEIGHT [mm] 56MPE 56MPS Adjusts the sealing position with respect to the belt. Values: AUTO / MAN. If set at AUTO sealing is performed at half the height of the product. Ideal for standard products. If set at MAN sealing is performed at the set measurement (measured starting from outfeed belt surface). Values: 0 ÷ 120.

OPENING SEALING BAR [mm] 56MPE 56MPS Adjusts the sealing bar aperture. Values: AUTO / MAN. If set to AUTO, opening the sealing bars is defined by the program. If set to MAN, opening is defined by the user (e.g.: to increase the speed of packaging, set the minimum opening of the sealing bars in order to reduce the closing and opening time).Values: 20 ÷ 100.

TYPE OF PHOTOCELL 56 56CS 56MPE 56MPS This function enables the operator to select the pack reader photocell. Values: HORIZ / VERT.

PHOTOCELL FILTER [s] 56 56CS 56MPE 56MPS Adjusts the length of time for which the photocell must ignore a missing signal (advisable when processing irregular product formats). Values: 0 ÷ 1. The next 2 screens allow data to be entered relating to the manual settings to be applied to the machine, so that every time this program is loaded, that memorised settings can be applied.

POSITION FILM TENSIONING ROLLERS ON TRIANGLES 56 56CS 56MPE 56MPS Enter the position of the wheels (R6) (OPTIONAL) with reference to the millimetre scale (X3) (see paragraph 5.4 PHASE 6). The function can be ON only if it is enabled in OPTIONALS.

BLOW AIR ACTIVATION 56 56CS 56MPE 56MPS Indicate whether the "AIR BLOW" kit is applied (ON) or not (OFF) for this program. Values: ON / OFF. The function can be ON only if it is enabled in OPTIONALS..

BELT SPEEDS [%] 56 56CS 56MPE 56MPS Adjust the infeed belt (IN) and outfeed belt (OUT) speeds from 6m/min. to 30m/min. Belt speed is identical for both.. Values: 20 ÷ 100.

BELT REVERSAL [mm] 56 56CS 56MPE 56MPS It can be set only if the “PACKET LENGTH” function is MAN. Adjusts the distance between the products. After the belts have stopped running, the infeed belt (IN) runs backwards in order to move the product back by the programmed distance. Values: 0 ÷ 500.

BELT STOP AT SEALING 56 56CS 56MPE 56MPS This function enables the operator prevent infeed belt (IN) from running during the sealing phase in order to ensure that the package is processed correctly. Values: ON / OFF.

LOAD BELT PHOTOCELL 56 56CS 56MPE 56MPS When this variable is set to ON, the machine prevents the infeed belt (IN) from running when in automatic START cycle, and activates it only when the load belt photocell is activated. (OPTIONAL). The function can be ON only if it is enabled in OPTIONALS.

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Chapter 5. Machine adjustment and setting up EN

FILM LOOSENING [mm] 56 56CS 56MPE 56MPS Adjusts the distance by which the film and product must be retracted before sealing, in mm (advisable when processing products over 200 mm in height). Values: 0 ÷ 250.

BELTS APPROACHING 56 56CS This function enables the operator to activate the system used to move the belts (IN) and (OUT) closer to sealing area when processing smaller pieces. Values: ON / OFF. The function can be ON only if it is enabled in OPTIONALS.

PUNCH 56 56CS 56MPE 56MPS This function activates the pneumatic perforator (OPTIONAL). Values: ON / OFF. The function can be ON only if it is enabled in OPTIONALS.

MARK READOUT 56 56CS 56MPE 56MPS This function enables a dedicated photocell (OPTIONAL) that reads the markers on opaque or coloured films. The function can be ON only if it is enabled in OPTIONALS.

UNWINDER DELAY [s] 56 56CS 56MPE 56MPS This function enables the operator to decrease the film tension on the triangles, delaying the moment when the unwinder starts running (advisable with products up to 100 mm in height). Values: 0 ÷ 3.

The next 3 screens allow data to be entered relating to the manual settings to be applied to the machine, so that every time this program is loaded, that memorised settings can be applied.

NUMBER OF MICROPUNCHES 56 56CS 56MPE 56MPS Enter the number of micro-punches (MF) to be positioned on the machine (see paragraph 5.4 PHASE 6).

FILM REEL POSITION 56 56CS 56MPE 56MPS Enter the film reel position with reference to the millimetre scale (X1) (see paragraph 5.4 PHASE 6).

FILM DRIVING ROLL POSITION 56 56CS 56MPE 56MPS Enter the position of the return roller (R5) with reference to the millimetre scale (X2) (see paragraph 5.4 PHASE 6).

REWINDER DELAY [s] 56 56CS 56MPE 56MPS This enables the operator to decrease the film tension on the rewinder rollers, delaying the moment when the rewinder stops running. Values: 0 ÷ 1.

The next 4 screens allow data to be entered relating to the manual settings to be applied to the any combined tunnel, so that every time this program is loaded, that memorised settings can be applied.

SPEED 56 56CS 56MPE 56MPS Enter the tunnel's conveyor belt speed.

INFEED T. 56 56CS 56MPE 56MPS Enter the temperature of the tunnel's infeed area.

OUTFEED T. 56 56CS 56MPE 56MPS Enter the temperature of the tunnel's outfeed area.

DEFLECTORS POSITION 56 56CS 56MPE 56MPS

Click on the ▲ and ▼ arrows to "graphically" represent the position of the tunnel deflectors. Note: This screen changes depending on whether the coupled tunnel is Tunnel 50, Tunnel 50 Twin, or Tunnel 70. There is only one temperature in Tunnel 50 (it does not change between infeed and outfeed) and there are 2 deflectors instead of 4.

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Chapter 5. Machine adjustment and setting up EN

LOAD BELT SPEED [%] 56 56CS 56MPE 56MPS Adjust the load belt speed with regard to the speed of the infeed belt (IN). Values: 20 ÷ 100. The function is only active if it is enabled in OPTIONALS.

LOAD BELT USE 56 56CS 56MPE 56MPS If set to OFF, it disables the load belt operation. Values: ON / OFF.

UNLOAD BELT SPEED [%] 56 56CS 56MPE 56MPS Adjust the unload belt speed with regard to the speed of the outfeed belt (OUT). Values: 100 ÷ 130. The function is only active if it is enabled in OPTIONALS.

UNLOAD BELT USE 56 56CS 56MPE 56MPS If set to OFF, it disables the unload belt operation. Values: ON / OFF.

PEDAL 56 56CS 56MPE 56MPS This function enables the operator activate the load belt using the pedal control (OPTIONAL), when processing multiple packages. Values: ON / OFF. The function can be ON only if it is enabled in OPTIONALS.

Once all variables have been displayed, press the button “Program configuration”.

Now press the button “Save” to save the changes made.

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Chapter 5. Machine adjustment and setting up EN 5.2.5. Parameter settings for the AUTOMATIC PROGRAM (from "graphic") In the previous pages, we have seen how it is possible to view/set the parameters for an automatic program by means of the "Data" key.Another method is explained in the following diagram, which enables you to view/set only the desired parameters, without having to scroll through all the screens. This is possible by selecting the relevant area from the machine's graphic.

45

Chapter 5. Machine adjustment and setting up EN

To memorise any modifications executed, press the " Program configuration " and "Save" keys.

5.2.6. Choosing the AUTOMATIC program To select an AUTOMATIC PROGRAM ensure the machine is in “CONDITION: Automatic STOP” and carry out the procedure described above.

Press the “Program configuration” button.

Press the ▼ arrow to view the list of saved programs.

Once you have selected the program, press the “Load” button.

The next 2 screens indicate the manual settings to apply to the machine. Press CONTINUE.

The first screen reminds you of the data with the manual settings to run on the Pratika 56: • number of micro-punches to use, • positioning of the film reel, • positioning of the return roller, • positioning of the film roller

wheels, • any activation of the air blow. Press TUNNEL SETTINGS (this screen only appears if the Tunnel coupled with the machine was selected in the CONFIGURATION menu).

The second screen reminds you of the data with the manual settings to run on the coupled retraction tunnel: • belt speed, • tunnel temperature, • position of air deflectors. Press OK .

Press the CLOSE button.

At this point, press the START button to run the AUTOMATIC cycle.

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Chapter 5. Machine adjustment and setting up EN 5.2.7. Parameter settings for the MANUAL PROGRAM Follow the procedure below to display the variables set in the MANUAL program.

Press the MANUAL button. At this point the programmable parameters display page appears; press the button to scroll through the various pages:

FRONT TEMPERATURE [C] 56 56CS 56MPE 56MPS Adjusts the front bar (short) sealing temperature. Values: 0 ÷ 240.

SIDE TEMPERATURE [C] 56 56CS 56MPE Adjusts the side bar (long) sealing temperature. Values: 0 ÷ 240.

SEALING TIME [s] 56 56CS 56MPE 56MPS Adjusts the bar sealing time. Values: 0 ÷ 3.

OPENING SEALING BAR [%] 56MPE 56MPS Adjusts the sealing bar aperture. Values: AUTO / MAN. If set to AUTO, opening the sealing bars is defined by the program. If set to MAN, opening is defined by the user (e.g.: to increase the speed of packaging, set the minimum opening of the sealing bars in order to reduce the closing and opening time). Values: 20 ÷ 100.

BELT SPEEDS [%] 56 56CS 56MPE 56MPS Adjust the infeed belt (IN) and outfeed belt (OUT) speeds from 6m/min. to 30m/min. Belt speed is identical for both. Values: 20 ÷ 100.

SEALING PRESSURE 56MPE 56MPS Regulates the pressure of the film sealing bar to optimise the cut. Values: MIN / MED / MAX.

CONVEYOR BELT FUNCTION 56 56CS 56MPE 56MPS It is the condition of use in which the machine works as a conveyor belt. The belts convey the products from the infeed area to the outfeed area, without being film wrapped. The sealing bar and opening film triangles fully open to allow the passage of products. Values: ON / OFF.

UNWINDER DELAY [s] 56 56CS 56MPE 56MPS This function enables the operator to decrease the film tension on the triangles, delaying the moment when the unwinder starts running (advisable with products up to 100 mm in height). Values: 0 ÷ 3.

PACKET HEIGHT [mm] 56 56CS 56MPE 56MPS

Press the ▲ and ▼ keys to adjust the opening of the triangles. Values: 35 ÷ 240mm. It is the height measured from the conveyor belt to the film lift bar (A) (see paragraph 5.5.3). Set a value of approximately 5mm more than the height of the product to packaged, in order to allow the product to pass.

SEALING HEIGHT [mm] 56CS 56MPE 56MPS

Press the ▲ and ▼ keys to regulate the sealing position respect to the product. Values: 0 ÷ 120mm.

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Chapter 5. Machine adjustment and setting up EN 5.2.8. Deleting a program To delete a saved program, simply load the program (e.g. P2) and proceed as follows:

Press the “Delete” button.

Press the “YES“ button. At this point the program has been deleted.

5.2.9. Choose the language To choose the language used on the display screen follow the procedure described below.

Press the “Setup” button.

Press the “Choosing the language” button.

It displays the list of available languages: IT (Italian), EN (English), FR (French), DE (German), ES (Spanish), PT (Portuguese), CS (Czech), NL (Dutch), TR (Turkish), RU (Russian). Press the key that corresponds to the language you wish to use and then the button.

5.2.10. Pause time This function is used to programme the machine's "pause" time. During this phase the sealing bar resistors switch off (a condition that ensures considerable energy savings), while all of the other machine functions stay on. This function is useful when you wish to switch off the resistors for a given amount of time, and when said amount of time has elapsed, they will heat up again (for example, this function is very useful for workers who, when they finish their lunch break, start their shift again and need to have the machine at the right temperature, ready to work; or for maintenance procedures requiring adjustments with the sealing bars off).

Press the PAUSE TIME key.

Press the keys for hours (h) and minutes (MM) to set the required pause time (minimum 15 minutes). Press the START key and then .

The main screen will display the amount of time remaining until the machine will start up again.

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Chapter 5. Machine adjustment and setting up EN 5.2.11. Partial and stock counter The PARTIAL COUNTER and STOCK COUNTER functions are only active in CONDITION: Automatic. PARTIAL COUNTER: the number on the touch screen indicates how many products have been processed since the

machine has been on. STOCK COUNTER: This function allows you to set the number of products requiring processing. Once the

number has been reached, the machine stops. The number on the touch screen indicates how many products the machine has processed

since the batch requiring processing has been set. To set the batch requiring processing, follow the procedure described here below.

Press the “Product counter” button.

Click on the text.

Enter the number of products (stock) to be packaged. Press “Enter”.

Number of products to pack (batch). Number of products packed since the machine was switched on. Partial count RESET button. Number of products packed in total by the machine (cannot be changed).

Press the “Main” button.

Note: when the number of products to package (batch) function is active, the "Product counter" key flashes.

Once the machine has packaged the programmed number of pieces, the „A025: STOCK OF MANUFACTURES ENDED” alarm is activated. To reset the alarm see paragraph 5.3. 5.2.12. Backup programs This function allows: • programs (recipes) memorised on the machine PLC to be saved to a USB key (Backup), • programs (recipes) memorised on a USB key to be imported into the PLC (Restore).

Press the “Program backup/restore” button and once the USB key has been inserted in the port behind the control panel, run “Backup” or “Restore” for the programs (recipes), following the displayed instructions.

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Chapter 5. Machine adjustment and setting up EN 5.3. Alarms The machine includes a series of ALARMS that are necessary in order monitor hazard and fault conditions. List of alarms: • A001: EMERGENCY ON • A002: OPEN GUARDS • A003: BYPASS SAFETY GUARDS • A004: BELT BREAKERS • A005: PRESSURE SWITCH • A006: SEALING BAR: PRODUCT PRESENCE • A007: SEALING BAR: TIME OUT MOVEMENT • A008: UNWINDER: EXCESSIVE FILM TENSION • A009: SCRAP: EXCESSIVE TENSION • A010: APPROACHING BELTS ERROR • A011: REWINDER FULL • A012: UNWINDER: REEL FILM IN EXHAUSTION • A013: UNWINDER: FILM FINISHED • A014: REWINDER: BROKEN FILM • A015: NO LINE AT OUTFEED CONVEYOR • A017: UNWINDER: TIME OUT • A018: WHEEL MOVEMENT TIMEOUT • A019: DRIVE ERROR • A020: INVERTER ERROR • A021: HOMING TIME OUT • A022: ON MAINTENANCE • A023: LOAD BELT EMPTY • A024: MACHINERY WARMING (this is reset when the machine reaches the programmed temperature) • A025: STOCK OF MANUFACTURES ENDED • A027: PHOTOCELLS: TIME OUT • A028: WHEEL MOVEMENT ERROR • A033: CENTER S: HIGH SWITCH HEIGHT PRODUCT TOO HIGH • A034: UNWINDER OUT POSITION • A035: HOMING NOT POSSIBLE: STOP MACHINE • A037: BELT IN INVERTER ERROR • A038: BELT OUT INVERTER ERROR • A040: INFEED BELT: NOT AVAILABLE • A041: OUTFEED BELT: NOT AVAILABLE • A042: BLADE DRIVE ERROR • A043: BELT ADVANCEMENT: INVERTER ERROR

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Chapter 5. Machine adjustment and setting up EN Each time an ALARM occurs, the machine stops and the "Alarm" key turns red. To reset the alarms, proceed as follows:

Press the “Alarm” button.

The display shows which alarm has been triggered. Press the text of the alarm and then the ► arrow to view the cause and solution.

Should there be more than one cause, press the key to read them all. At this point, press the key and follow the instructions to solve the problem.

Press the “Alarm reset” button, then .

The alarm has been reset.

Note: in the case of the “A002: OPEN GUARDS” alarm only, the RESET (S2) button starts flashing.

To reset this alarm, proceed as follows: Close the guard. Press the RESET (S2) button.

The machine is fitted with “EMERGENCY Pushbutton” (S1) that stop the machine instantaneously when pressed, interrupting the work cycle.

To reset this alarm, proceed as follows: Remove the cause of the alarm. Release the “EMERGENCY Pushbutton” (S1) by rotating it to the right. Press the RESET (S2) button. PLC diagnosis

Battery charge status

Code of last cause of application error

Code of last cause of PLC STOP

PLC version

HMI version

The “PLC diagnosis” key displays some information on the PLC status. It is useful when diagnosing problems.

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Chapter 5. Machine adjustment and setting up EN 5.4. Introducing of the film To insert the film, the machine must be in “Manual START” mode. Rotate the “BYPASS SAFETY PROTECTIONS” (S3) switch to on, and open the front and back guards.

PHASE 1

To make it easier to position film reel, extract the reel support carriage (C) by lowering the handle (M1) and pulling the carriage out. Position the film reel on the rollers (R1) and (R2). The open end of the film must always be in the position indicated by the arrow. (Note: the reel unwinding direction must always be specified when ordering the film). Introduce the film as shown in the figure. To make it easier to introduce the film, press the button on the right of the reel. Press and hold this button to activate the motorised roller that the reel rests on in order to release the required quantity of film. Insert the two film flaps, one above and one below the upper guide triangle (Ts). Grasp the two ends of the film and unwind about 1 metre.

PHASE 2

Take the lower edge of the film corresponding to the rear edge of the inversion triangle and feed it under the lower triangle (Ti) from the outside towards the inside and over the feeder belt (N1).

PHASE 3

Next, feed the upper edge of the film over the upper triangle (Ts).

PHASE 4

Move the final part of the film (#) that passes through the triangles and to the left, in parallel with the feeder belt (N1) and feed the film under and over the feeder belt, aligning it with the sides immediately after the end of the belt.

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Chapter 5. Machine adjustment and setting up EN PHASE 5 (Pratika 56, 56CS, 56MPE)

Feed the film between the two rollers (R3) and the two wheels (R4) on the feeder. At this point perform a number of sealing cycles by pressing the “Sealing” key, so as to create a length of film that is long enough to complete insertion as shown in the diagram. In order to seal the film you must close the front (C1) and back (C2) guards. Lastly, tie the film onto the pin attached to the rear flange (F).

PHASE 5 (Pratika 56 MPS)

Place the end of the film between the two wheels (R4) of the dragging device. Been holding the “Conveyor belt movement” key pressed, the film is drawn inside the unit where it is sealed. Press the “Conveyor belt movement” key until a sufficient strip of film is implemented to complete insertion according to the layout shown. Lastly, tie the film onto the pin attached to the rear flange (F).

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Chapter 5. Machine adjustment and setting up EN PHASE 6 Effect the manual settings (paragraph 5.2.4) optionally stored in the program being run.

Position the number of micro-perforators (MF).

Position the film reel. See millimetric scale (X1).

Position the return roller (R5). See millimetric scale (X2).

Position the film roller wheels (R6) (OPTIONAL) on the triangles. See millimetric scale (X3).

PHASE 7

Next, adjust the positioning bars (B), regulating the knob (M3) in order to lock the reel, and leaving a gap of 5 mm between the bars and the reel. Note: The reel is positioned correctly when the left edge of the film (viewed from the rear of the machine) is at a

distance A, equivalent to half the distance H (aperture of the triangles).

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Chapter 5. Machine adjustment and setting up EN 5.5. Adjustments 5.5.1. Adjusting the infeed belt Adjust the position of the infeed belt (N1) according to the width (L) of the product to be packaged. Loosen the knob (M1)and adjust the position of the belt so that the product has a minimum amount of play between the guiding rod (approx 20mm) and the rear frame of the belt (approx 10mm).

5.5.2. Adjusting the photocells The machine is set up for the positioning of the vertical reading photocell (B5) recommended for extra low products and the horizontal photocell (B6) recommended for extra narrow products. It is also possible to modify the distance between photocell and the sealing bar in order to optimise the way the products are inserted. 5.5.3. Adjusting the film raiser bar The bar (A) is used to raise the film correctly while the product is being inserted. Loosen the knob (M2) and move the bar to the left when packaging short products. Move the bar to the right when packaging tall products.

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Chapter 5. Machine adjustment and setting up EN 5.5.4. Adjustment of film opening bar The bar (A1) allows to separate the 2 edges of the film reel. Position the bar inside the 2 edges of the film so that the end is 1 cm behind the crease of the film. Note: See paragraph 5.4: PHASE 1.

5.6. Packaging Once all adjustments have been made, the machine is ready to start working. With the machine in condition “Automatic STOP” press the START key. The belts will begin operating and it is possible to place the products on the infeed belt. When the product travels along the outfeed belt, the sealing frame descends to seal the film. The packaged product advances towards the roller conveyor or inside the tunnel to shrink the film.

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Chapter 6. Ordinary maintenance EN 6.1. Precautions and setting to maintenance mode

CAUTION! • Maintenance must be performed exclusively by skilled personnel familiar with the machine. • Never carry out maintenance, lubrication, or repairs when the machine is in operation and/or

connected to the power supply. • Never carry out maintenance on moving parts. • After each operation re-mount any guards that have been removed, and bring the machine back to

its original state. • Always observe all safety standards as specified in this manual and these currently applied in the

country of installation. SETTING THE MACHINE TO THE MAINTENANCE MODE This procedure must be performed before all routine maintenance,cleaning and special maintenance, to shut off the machine from all power sources, as follows: • Switch the machine off by rotating the main switch (Q1) to “0” (OFF) • Remove the plug from the mains socket • WAIT 15 minutes to allow the capacitors to discharge. 6.2. Maintenance table

6.2.1. Routine maintenance plan This type of machine is designed for minimal maintenance; however always observe Maintenance schedule set out below.

FREQUENCY COMPONENT OPERATION Every day

Machine Remove all residue for product processing which may impair correct machine operation.

Every day

Blades Clean surfaces that come into contact with the film, using cloths or paper. Never use objects that may damage the surfaces.

Every 12 months

Supports Carry out lubrication with grease type:NLGI 2.

Every 12 months

Gear couplings Ensure sufficient lubrication.

Every 3 months

Blades and contrast bars Check the condition of the adhesive teflon strips and silicon plate.

WARNING! Gears reduction unit are lubricated with “permanent” type synthetic oil and therefore do not require lubrication. 6.2.2. Maintenance plan of safety devices The periodical control of the “SAFETY DEVICES” listed in the table is required.

FREQUENCY COMPONENT OPERATION Each month

Front and back guards Opening the front and back guards (both in manual and automatic mode).

Check the consequences: luminous and acoustic alarm, the machine blocks.

Each month

Sealing bar guards

Movement of guards placed around sealing bar near four sensors (in manual mode)

Check the consequences: luminous and acoustic alarm, the machine blocks.

Each month

Pushbutton EMERGENCY

Activation of emergency button (manual and automatic mode)

Check the consequences: luminous and acoustic alarm, the machine blocks.

Record of control Each control of the safety devices must be recorded, indicating the data and result of the control performed: date of check, inspector, result.

Reporting fault Should a fault be detected, contact the Assistance Service of the Supplier for its restoration.

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Chapter 6. Ordinary maintenance EN 6.3. Disassembling, demolition and elimination of residuals

ATTENTION! All disassembling and demolition operations must be done by qualified personnel with mechanical and electrical expertise required to work in safe conditions.

Proceed as follows: disconnect machine from power mains disassemble components All wastes must be treated, eliminated or recycled according to their classification and to the procedures in force established by the laws in force in the country where the equipment has been installed.

The symbol indicates that this product shall not be treated as household waste. By making sure that the product will be properly disposed of, you will facilitate the prevention of potential negative effects for the environment and human health, which might be otherwise caused by the improper waste treatment of this product. For more detailed information about the recycling of this product, please contact the product seller or, as an alternative, the after-sales service or the corresponding waste treatment service.

Chapter 7. Guarantee EN 7.1. Certificate of guarantee The guarantee runs for 12 months after the installation date under the conditions set out in the instruction manual. Fill in the card with all data requested, tear out along the perforations and send in. 7.2. Guarantee conditions The guarantee runs for 12 months and comes into force on the installation date of the machine. The guarantee covers free replacement or repair of any parts due to defects arising from faulty material. The repairs or replacement are usually carried out at the manufacturer’s premises, with transport or labour charged to the buyer. If the repair or replacement is carried out at the buyer’s premises, he shall bear the travelling, transfer and labour costs. Work under guarantee can be carried out exclusively by the manufacturer or by the authorised dealer. In order to be entitled to repairs under the guarantee, the faulty part must be sent for repair or replacement to the manufacturer or his authorised dealer. The return of such repaired or replaced part will be considered fulfilment of the guarantee. The guarantee is voided: in case of failure to mail the CERTIFICATE OF GUARANTEE, duly filled in and signed, with in 20 days after the

date of purchase. in case of inappropriate installation, power supply, misuse and mishandling by unauthorised persons. in case of changes made to the machine without prior agreement in writing from the manufacturer. if the machine is no longer the property of the first buyer. The manufacturer declines all liability for personal injury or damage in case of inappropriate installation or connection to the power mains or omission of connection to earth or in case of any mishandling of the machine. The manufacturer undertakes to carry out any variations and changes made necessary by technical and operating requirements.

IN THE EVENT OF DISPUTES THE COURT OF BERGAMO (ITALY) SHALL HAVE SOLE JURISDICTION.

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